YASKAWA GPD 505/P5 Programming manual

PP.P5G5.03.Troubleshoot
Page 1
Rev. 06/11/2003
Yaskawa Electric
America
Unit Troubleshooting Manual
Section Three:
Fault Codes & Appendix
GPD 506/P5 and GPD 515/G5
(0.4 ~ 160kW)

PP.P5G5.03.Troubleshoot
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Rev. 06/11/2003
Section Three:
Fault Codes
GPD 515/G5
DSPL ENTER
DIGITAL OPERATOR JVOP-131U
FREF FOUT IOUT
ACCEL
F/R
V/F
VMTR
FLA PID
DECEL
FBIAS
OC
RUN STOP
RESET
LOCAL
REMOTE
REMOTE
REF
SEQ
kWout
MONTR
FGAIN
kWsav PRGM
GPD 505/P5 GPD 506/P5

PP.P5G5.03.Troubleshoot
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Rev. 06/11/2003
Fault Codes
The GPD 506/P5 and GPD 515/G5 inverters can store up to (4) faults.
The GPD 515/G5 inverter has a fault trace that saves the drive status
at the time of the fault, and a fault history indicating elapsed time of
the stored faults.
The fault codes can be grouped into (3) categories:
Major Fault - Motor coasts to a stop, the fault is displayed on the
digital operator, and the fault relay is activated.
Minor Fault - Operation continues and the fault flashes on the
digital operator. The fault relay does not activate.
Parameter Setting Error - Inverter can’t run. The fault is
displayed on the digital operator, and the fault relay is not activated.
A complete list of fault codes may be found in the appendix.

PP.P5G5.03.Troubleshoot
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506 √515 √505 Undervoltage of the main circuit when running.
230V Units - trip point 190V DC or less.
460V Units - trip point 380V DC or less.
600V Units - trip point 546V DC or less.
UV1
DC Bus Undervolt Uu1
Undervoltage of the control circuit when running.
230V Units - 30kW ~ 75kW, monitors the (-15V)
power supply.
460V Units - 55kW ~ 160kW, monitors the (-15V)
power supply.
UV2
CTL PS Undervolt Uu2
Possible Cause(s): Single phase condition on the input, low input voltage at L1, L2, and L3.
Corrective Action: Check the three phase input voltage, verify L2-05 for 515/G5 units.
Possible Cause(s): External load connected pulling down the inverter power supplies.
Corrective Action: Repair or replace the power/gate drive board.
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.

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Rev. 06/11/2003
The pre-charge contactor opened while the inverter is
running.
UV3
MC Answerback Uu3
Overvoltage of the main circuit when running.
230V Units - trip point 400V DC or more.
460V Units - trip point 800V DC or more.
600V Units - trip point 1050V DC or more.
OV
DC Bus Overvolt ou
This fault only applies to 230V units 18kW ~ 75kW , 460V units 22kW ~ 160kW and
600V units 30kW ~ 160kW .
Possible Cause(s): Contacts on contactor are dirty, contactor does not function mechanically.
Corrective Action: Check the contactor, check the ribbon cable from the control board to the
gate drive board.
Possible Cause(s): High input voltage at L1, L2, and L3. The deceleration time is set too
short. Power factor correction capacitors are being used on the input to the inverter.
Corrective Action: Check the input circuit, verify the program parameters, add a braking
resistor, remove the power factor correction capacitors.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √

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Designed to protect the inverter.
Output current has exceeded OC level of the inverter
rated value instantaneously.
OC
Over current oc
Designed to protect the inverter.
Inverter output grounding current has exceeded 50%
of the inverter rated current.
GF
Ground Fault gf
Possible Cause(s): Shorted inverter output phase to phase, shorted motor, locked rotor.
Corrective Action: Remove the motor and run the inverter without the motor. Check the
motor for a phase to phase short. Check the inverter for a phase to phase short at the output.
Possible Cause(s): Motor lead shorted to ground, DCCT defective.
Corrective Action: Remove the motor and run the inverter without the motor. Check the
motor for a phase to ground short. Check the output current with a clamp on meter to verify the
DCCT reading.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
OC – 200%
20P4 – 2015
40P4 – 4015
51P5 - 5160
OC – 180%
2018 – 2075
4018 – 4160
506 √515 √

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The inverter output is short-circuited.
SC
Short Circuit sc
Detects if the DC bus fuse has opened.
PUF
DC Bus Fuse Open PUf
Possible Cause(s): Shorted output transistor, shorted main circuit component.
Corrective Action: Remove power from the inverter and disconnect the motor. Perform the
checks without/with power starting on page 10. Replace the shorted component(s), then
replace the defective fuse.
505
Possible Cause(s): Shorted inverter output phase to phase, shorted motor, locked rotor.
Corrective Action: Remove the motor and run the inverter without the motor. Check the
motor for a phase to phase short. Check the inverter for a phase to phase short at the output.
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √

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Rev. 06/11/2003
Motor overload, designed to protect the motor.
Fully adjustable from parameter setting (n033 and
n034 for 506/P5 and E1-02 and E2-01 for 515/G5)
A pre-alarm can be selected as a minor fault by using
the multi-function outputs.
OL1
Motor Overloaded ol1
Inverter overload, designed to protect the inverter.
120 or150% of inverter rated current for 1 minute.
515 - 150% for 1 minute
505 and 506 - 120% or 150% depending on drive
capacity and setting parameter n116
OL2
Inv Overloaded ol2
Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √

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Rev. 06/11/2003
ol3 Over torque detection function.
A customer programmable current detection. Response
may be selected. A minor fault contact output can be
programmed by using the multi-function outputs.
OL3
Overtorque Det 1
OL4
Overtorque Det 2 N/A Over torque detection function (2).
A customer programmable current detection.
Response may be selected. A minor fault contact
output can be programmed by using the multi-function
outputs.
505
Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √
505
506 515 √

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Rev. 06/11/2003
Inverter input power supply has an open phase.
Large imbalance of input voltage.
PF
Input Pha Loss sp1
Inverter output has an open phase.
LF
Output Pha Loss spo
Possible Cause(s): Open phase on the input of the inverter. Loose terminal screws at
terminals L1, L2, or L3. Program parameters set incorrectly (n083 for 506/P5, L8-05 for 515/G5)
Corrective Action: Tighten the terminal screws, check the input voltage, verify the program
settings.
Possible Cause(s): Open phase on the output of the inverter. Loose terminal screws at
terminals T1, T2, or T3. Program parameters set incorrectly.
Corrective Action: Tighten the terminal screws, check the output voltage, verify the
program settings.
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
505
506 √515 √
506 515 √505

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Rev. 06/11/2003
The motor speed has exceeded the overspeed level
when operating in the Closed Loop V/f or Closed
Loop Flux Vector modes.
OS
Overspeed Det N/A
Feedback pulses are not received by the PG option
board.
PGO
PG open N/A
Possible Cause(s): The load has changed considerably, the program settings may not be
set correctly.
Corrective Action: Check the load on the motor, verify the program settings (F1-08 PG
Overspeed Level, and F1-09 PG Overspeed Time).
Possible Cause(s): The Pulse Generator feedback wires may be broken or not properly
connected to the PG feedback option board.
Corrective Action: Check for a broken wire or a loose connection from the Pulse
Generator, verify the program settings.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 515 √
505
506 515 √

PP.P5G5.03.Troubleshoot
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Rev. 06/11/2003
The braking transistor has failed.
230V Units - 0.4kW ~ 7.5kW
460V Units - 0.4kW ~ 15kW
RR
DynBrk Transistr
The braking resistor temperature has exceeded the
allowable value.
(Protects Yaskawa 3% duty cycle resistors only)
Can be selected as a minor fault by using the multi-
function outputs.
RH
DynBrk Resistor
Possible Cause(s): Shorted braking transistor, high DC bus voltage, defective braking
resistor.
Corrective Action: Replace defective transistor or resistor, monitor DC bus level.
Possible Cause(s): Overhauling load, extended braking duty cycle, defective braking
resistor.
Corrective Action: Verify braking duty cycle, monitor DC bus voltage, replace resistor.
505
N/A
N/A
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √

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Rev. 06/11/2003
The actual torque during deceleration has reached
the regen torque limit for more than 3 seconds.
(Open Loop Flux Vector mode only)
CF
Out of Control N/A
In the zero servo mode, the motor shaft has
rotated 10,000 non-quadrature PG pulses from the
home position.
SVE
Zero Servo Fault N/A
Possible Cause(s): The regen torque limit value is set too low, load torque is excessively
large.
Corrective Action: Verify the program setting, L7-03 forward regen torque limit and L7-04
reverse regen torque limit, extend the deceleration time.
Possible Cause(s): Torque limit or zero servo gain set too low, load torque excessively
large, PG signal noise.
Corrective Action: Verify the program parameters B9-01 zero servo gain and torque limit
settings L7-01 ~ L7-02, check for noise on the PG signals.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 515 √

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Rev. 06/11/2003
oh2 The transistor cooling fin temperature exceeded the
allowable value. 506/P5 (105 ° C), 515/G5 (105 ° C)
OH1
Heatsnk MAX Temp
Possible Cause(s): Cooling fan(s) are not working, high ambient temperature.
Corrective Action: Check for dirt build-up on the fans, reduce the ambient temperature
around the inverter.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
The inverter will stop if the digital operator is removed
when the inverter is commanded to run through the
digital operator.
OPR
Oper Disconnect
Possible Cause(s): The operator is not attached, broken operator cable.
Corrective Action: Attach the digital operator, check the cable connected to the digital operator,
verify the program setting of parameter O2-06 for 515/G5 models and n112 for 506/P5 models.
op
506 √515 √

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Rev. 06/11/2003
The CPU on the SI-F/G option board has stopped
operating.
E-10
SI-F/G CPU down
Possible Cause(s): Defective option board, electrical noise effecting operation.
Corrective Action: Cycle power, replace the option board.
Possible Cause(s): Connection is broken, master has stopped communicating.
Corrective Action: Check all connections, verify all user side software configurations.
E-15
SI-F/G Com Err After initial communication has been established, the
connection was then lost.
Response may be selected.
505
N/A
N/A
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
♣E-10 and E-15 fault codes may only appear when using the OMRON specification (O2-09=3).
♣
♣
506 515 √

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After initial communication has been established, the
connection was then lost.
Response may be selected.
BUS
SI-B Com Err
Possible Cause(s): Connection is broken, master has stopped communicating.
Corrective Action: Check all connections, verify all user side software configurations.
505
N/A
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
Possible Cause(s): Connection is broken, master has stopped communicating.
Corrective Action: Check all connections, verify all user side software configurations.
CE
Memobus Com Err
Transmission error. Control data was not received
normally when the power supply is turned on.
Response may be selected.
ce
506 515 √
506 √515 √505

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External fault at terminal number 3.
EF3
External Fault3 ef3
External fault at the multi-function inputs terminal
number 4 ~ 8. 506 is the same as 505 and only has
EF 4-6.
EF4~8
External Fault ef4
~6
Possible Cause(s): An external fault condition exists connected to terminal number 3.
Corrective Action: Check for an external condition, verify the program parameters.
Possible Cause(s): An external fault condition exists connected to one of the terminals 4,
5, 6, 7, or 8.
Corrective Action: Check for an external condition, verify the program parameters.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √

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ef2 External fault at the multi-function input terminal
number S2.
Possible Cause(s): An external fault condition exists at terminal S2.
Corrective Action: Check for an external condition at terminal S2, verify the program
parameters.
ef0 External fault from serial communication.
Possible Cause(s): An external fault condition exists.
Corrective Action: Check for an external condition, verify the program parameters.
505
EF0
External Fault
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √
506 √515 505
EF2
External Fault

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Rev. 06/11/2003
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
EEPROM internal data does not match the value in
RAM when setting a parameter.
ERR
EEPROM R/W Err N/A
Possible Cause(s): Control board hardware failure.
Corrective Action: Cycle power, replace the control board.
The deviation of the speed reference and speed
feedback has exceeded the regulation level.
A minor fault contact output can be programmed by
using the multi-function outputs.
DEV
Speed Deviation N/A
Possible Cause(s): The load has changed considerably.
Corrective Action: Check the load on the motor, verify the program settings (F1-10 PG
Deviate Level, F1-11 PG Deviate Time. F1-04 PG Deviation Select.
506 515 √

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CPF00
Com-Err(OP&INV) Transmission between the inverter and the operator
cannot be established 5 seconds after supplying
power.
cpf0
Possible Cause(s): Digital operator cable not securely connected, digital operator
defective, control board defective.
Corrective Action: Check the operator cable, replace the digital operator, replace the
control board.
CPF01
Com-Err(OP&INV) Communication fault between the inverter and the
operator has occurred for more than 2 seconds.
cpf1
Possible Cause(s): Digital operator cable not securely connected, digital operator
defective, control board defective.
Corrective Action: Check the digital operator cable, replace the digital operator, replace
the control board.
505
Fault Codes
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
506 √515 √